Molding composition and process of making same



Patented New. 11?, E933 F HONTCIIAIB, NEW EY, ASSIGNOR TO E s F A COOBA'I'IOH OF NEW JERSEY MOLDING COOSITION E0 ma.

This invention relates to molding compositions containing sulphur as the essential binding agent and to the process of making same and relates particularly to the employment @1 of sulphur in a dispersed form in the preparation at such molding compositions.

en sulphur is ground with water in the presence of a dispersing or peptizing agent, particularly clay material and especially E0 bentonite. the sulphur may be obtained in a dispersed condition which is especially suitable for mixing with a porous or fibrous filler such as sawdust or ground wood.

If the sulphur is melted with the wood or w it it is ground therewith without first dispersing it, results of a satisfactory character with respect to strength, finish of the surface and the like are not as advantageously obtained. The dispersed sulphur appears to have the. property of impregnating such a porous or fibrous filler. at least to a certain degree andbv virtue of such intimate admixture molded products having an excellent surface and relatively high strength result. In one case 10 parts by weight of bentonite, 90 parts by weight of lump sulphur, 300 parts of water and part of coloring agent were employed. The sulphur was ground with the water in a ball mill for 3 hours. the bentonite added and grinding continued for 3 hours,

finally the coloring agent added and the mixture was ground for a further period of one half hour.

A material so prepared (or prepared in a similar manner it the coloring matter is omitted) is a fine suspension of a creamy consistency. referred to herein as a dispersion of sulphur. This creamy mass contains the sulphur in an extremely finely divided state. hut the sulphur is not dissolvedas it. would= dissolve in carbon bisulphide,

for example), because the liquid present, water, is not a solvent for sulphur. The suspension of sulphur is quite stable and the 5 minute particles of sulphur and of bentonite are in intimate association. The particles of sulphur are very minute. and are seemingly in a condition approaching colloidal suspensum.

50 parts by weight of this dispersion, 50

.fected by water.

Application filed December 4, 1924. Serial m5. 753,986.

parts of water and 25 parts of wood flour were mixed and the composition dried in an oven for 3 hours at 105 C.

For molding this mixture was placed in a hot mold pressed at a temperaure of 140 C. and a pressure of 1000 unds and the mold was cooled somewhat efore opening. in this way a molded article of smooth finish was obtained.

The proportion of sulphur to round wood ea or wood flour may be varied. or example the composition may contain approximatel equal parts of sulphur and the ground woo Other fillers such as various mineralpowders, asbestos fibre, cotton flock and the like as may be used, also fireproofing agents such as borax. boric acid. ammonium phosphate etc. The dis ersion of the sulphur is facilitated by adding a small amount'of quick lime.

For examp e 1 part by weight or quick lime 3'0 to 00 parts ofthe mixture of bentonite and sulphur. The proportion ofbentonite to sulphur maybe varied but I prefer to use 1 part or less of bentonite to 9 parts of sulphur in order that the composition may have a good degree or resistance to water. If the proportion of hentonite is much greater than this the molded material is more likely to be ai Other hydrated clays other than bentnnite 8 may be used and in some cases also auxiliary agents such as casein. starch. glue, water glass and the like. Or anic agents are however generally undesirable as they are likely to cause the sample to mould if exposed to damp conditions. Be onite in neutral solution'or with an auxiliary binder such as water elass or with an alkaline agents such as calcium hydroxid. barium hydroxid etc. is preferable for most purposes.

- The molding composition may be formed into the renuired shape by placing in a mold, inserting the mold in hot press. pressina: to cause the sulphur to flow and then chilling. A preferable mode is that of placing the com- 95 position in a mold which has been heated on a hot plate to a temperature sufiicient to cause the sulphur to flow, then put the mold immediately in a cold press. The heat of the mold is sutiicient to cause the molding com- 109 ill ' persed sulphur position to form n. sharp outline of the mold before cooling action occurs. In this way instead of using two presses the operation can be carried out with a. single pressing.

In place of wood flour, sawdust may be employed and one form which has utility is made from cedar sawdust or cedar chips. These are e. lay-product of cedar saw mills. Some cedar sawdust finds s. market, to be used for the extraction of cedar oil, but the demand for this is sullicient to utilize only asmull portion of such. lay-product. The disaffords a cheap binding agent by means of which the cedar chips can be molded into various shapes for example into slabs which may be used as substitute for ceder wood, .18 wall board for use in making cedar closets or for decorative purposes, for making cedar chests and other purposes for "h artificial lumber containing cedar sawdust, shavings or chips is applicable. Also it is possible to mold a layer oi the cedar chip composition on a backing of ordinary wood which can he used for any suitoble construction. Cedar dust may be employed as pencil stock. For example it may be molded about a core of pencil lead. In this way it may be used as s substitute for the wood commonly employed in making lead pencils.

The cedar chips may be mixed with the dispersed sulphur in any suitable proportion. When the material is to be molded into tablets or other'shapes to be employed as a moth repellent it is preferable to have the proportion of sulphur low so as to secure 5. considerable degree of porosity to allow the oil of cedar to escape gradually. llt should be noted that the cedar dust or chips em-- ployed for this purposemey be fortified if desired by the addition of oil of cedar. Likewise it is possible to use'ordi'hary wood flour or other wood which does not contain cedar as a medium for carrying cedar oil. such. treated wood being made into molding composition with the dispersed sulphur.

@n the other hand when the cedar sawdust is to be employed as a. molding composition requiring a. good finish a higher proportion of sulphur may be used. from one-third the total mixture (dry weight) to equal parts of sulphur and cedar wood or 'even a larger proportion of sulphur. The water dispersion may be colored with dyestuffs for enanr plc a pink or rose color may be employed so that the sulphur b nder does not show distinctly in the molded composition. It is often desirable to have the hinder as near the color of thewood being imitated possible.

In accordance with the present invention itis proposed to make a shingle from cedar sawdust chips or other wood sawdust chips, shavings, wood flour, pulp and the like with sulphur preferably with the addition of a scanner fireproofing agent end preferably with the employment of colors, with sulphur, the amount of the letter preferably being at least one-third of the weight of the wood and preferably approximately equal in wei ht to the wood, in order to secure a sullicient degree of resistance to moisture.

In some cases the wood fragments may be dyed different colors so that when molded a multi-colored shaped article results.

In employing sulphur in a. dispersed form for molding purposes experiments have shown that the presence of any substantial amount of moisture in the composition is very liable to cause blackening of the molds, when the latter are of steel or iron. It is therefore desirable to heat or otherwise dry the composition to a state such that it is devoid of discoloring or blackening action on molds. In fact in employing molds of an elaborate character and of expensive construction the cost of upkeep would be considerable if blackening occurred as the fine polished surface oi the mold would be destroyed. In the preferred form of the invention such method of drying is not mere- 1y desirable but is essential.

The foregoing description has been based on the employment of sulphur in a dispersed form but I do not limit myself to such form as this represents only the preferred embodiment. I include any method of incorporatin sulphur with a porous or impregnatable filler which accomplishes very intimate admixture thereby affording products of good strength and desirable surface finish.

Bythe term dispersed sulphur as used herein, 1 mean sulphur existing in a finely divided condition, mixed with much more than its own amount of 0. liquid medium in which sulphur is insoluble. such sulphur beiug in intimate association with a solid material which is more readily wetted by said liquid medium than is sulphur. the said sulphur being readily suspendzible in water, after drying. to produce a stable suspension. The original suspension can also be diluted with water to form a stable suspension. By the term dispersion of sulphur I mean. a fluent suspension containing dispersed sulphur (as above defined) in a liquid, e. g. water, in which sulphur is. insoluble. By the term water dispersed T mean that water is the basis of the liquid in which the dispersion is effected.

'VVhat I claim is:-

1. The process of making a molding composition which comprises the steps of grindlBfI sulphur with water and bentonite to form a creamy liquid dispersion and incorporating the latter with comminuted wood.

2. The process which comprises incorporating' fragments of wood with a water-dispersion 01': sulphur in a wuter-bentonitc compo- I sition containing a small amount of quick- 3. The process of making artificial wood 7 material which comprises incorporating fragments of wood with a Water dispersion of sulphur, and hot pressing the resultant material.

material which comprises incorporating fragments of woodwith a water dispersion of sulphur, drying, hot pressing, and chilling the resultant material.

5. The process which comprises dispersing sulphur in an aqueous medium and intimately mixin, such dispersed sulphur'in the form of a creamy mass in such aqueous medium,-

with comminuted wood.

6. A process which comprises grinding sulphur with water and a dispersion-assisting colloid material of the class including hydrated clay, gum trae'acanth, and starch.

until a creamv aqueous dispersion is formed,

drying such dispersion,.mixing the same with a wood filler at any convenient stage, and molding the dried mixture under heat and pressure.

7. A process which comprises dispersing sulphur in an aoueous medium, into the form of a substantially smooth creamy mass, and intimately mixing such creamy mass with comminuted wood.

8. A process whichcomprises dispersing sulphur in an aqueous medium with bentonite, to produce an aqueous creamy mass containing very finely divided sulphur, and incorporating such creamymass with comminuted wood.

9. The process of making a molding composition which comprises the stcps of grinding sulphur with water and bentonite to form a creamy liquid dispersion and incorporating the latter with comminuted cedar wood, drying and hot pressing.

CARLETON ELLIS.

4. The process of making artificial wood 

